Nuclear Government of Corporation of Power India

Nuclear(A Government
Powerof Corporation
India Enterprises)
of
India Ltd
KUDANKULAM NUCLEAR POWER
PROJECT
M.S.Suresh
Indian Nuclear
Program
Energy Comparisons
1 kg Coal 3 kw.h
1 kg Oil 4 kw.h
1 kg Uranium 50000 kw.h
(3,500,000 kw.h with closed fuel cycles)
Fuel Required for 1000 MWe Plant (annual)
Coal 2,600,000 t 2000 train of 1300 t each

Oil 2,000,000 t 10 super tanker
Nuclear 30t 10 m3 of reactor core
(Uranium)
Land Required for 1000 MWe Plant
Fossil Nuclear Site 1-4 km2

Solar (thermal or Photovoltaic) 20-50 km2 (a small city)
Wind Field 50-100 km2
Bio Mass Plantation 4000-6000 km2
BASICS OF NUCLEAR ENERGY
The source of Nuclear Energy lies in the

equivalence of mass and energy according to
Einstein’s equation:
2,
E=mc
where E is the Energy, Joules
c is the velocity of light, m/s
m is the mass, kg
HOW A NUCLEAR REACTOR WORKS ?
INDIAN NUCLEAR POWER PROGRAMME
 Stage – I: 10,000 MWe through

PHWRs and LWRs.
LWR
 Stage- II: Fast Breeder Reactors
with plutonium as fuel and
thorium as blanket for breeding U-
233.
 Stage-III: Breeder Reactors using
U-233 as fuel and thorium as
blanket.
 Short term goal is to complement
generation of electricity at
locations away from coal mines.
 India’s long term nuclear energy
policy is based on recycling
nuclear fuel and harnessing the
available thorium resource.
 Energy potential of three stage
programme is placed more than 3
times the energy potential of coal
reserves.
INDIAN NUCLEAR POWER PROGRAMME
 PHWR- Pressurized Heavy water Reactor

Fuel-Natural Uranium LWR
Moderator- Heavy Water D2O
Coolant – Heavy water
PWR- Pressurized water Reactor

Fuel-Enriched Uranium
Moderator- Water
Coolant –Water
FBR - Fast Breeder Reactor
Fuel - Plutonium
Coolant – Liquid sodium

INDIAN NUCLEAR POWER PLANTS
In Operation -3310 MWe Under Constn-3920MWe
Narora 2x 220
Rawatbhata
1x 150
Kakrapar 1x 200
2x 220
2x 220 2x 220
2x 160, 1x540
1x 540
Tarapur
In Operation -15
2x 220
Kaiga 2x 220 Under Construction- 8
Kalpakkam
2x 200
1x 500 (PFBR )
Kudankulam
2x 1000
NPCIL: BEST PERFORMING PSU
• AAA rating continuously for last 4 years
• NPCIL’s Kakrapar NPP was adjudged the best

performing plant PHWR in the world.
• President’s award for the excellent performance in the

power sector in year 2003-04
• Highest capacity factors in the world among PHWRs

(>90%)
• All plants of NPCIL are ISO 14000 certified.
• Highest record in the industrial safety

rief Background of KKNP
SITE SELECTION
• Site cleared by DAE Site Section Committee

for setting of 4x500 MWe. - 1988.
• Clearance from AERB for Site & High Power
Committee on Tamilnadu Government for
environmental obtained.
• Site investigation for 4x500 MWe including
Bore holes were started in 1987-88.
• Site was subsequently allotted for 2x1000
MWe VVER Plant.
CLEARANCES FOR KKNPP
• Tamilnadu State Environmental Committee
Clearance .
• Clearance from Tamilnadu Forest
Department.
• Clearance from Ministry of Environment &
Forest,
• 500m shoreline clearance from PM’s office.
• Clearance of committee on conservation of
seashore for location of Atomic Power
Station at Kudankulam from Tamilnadu Govt.
• Clearance from AERB for Excavation.
• Clearance from AERB for Construction of
KKNPP
HYDROTECHNICAL STRUCTURES (INTAKE AND OUTFALL)
Discharge channel
Part of essential load pipeline

Breakwater dyke
Chlorination plant
Shoreline protection bund

UZP
Sea Water Intake pipeline
Fish protection facility
Intake Structures
Bridge
Sea Water Inlet pipeline
Forebay
Siphon walls
Main pump house
CIVIL WORKS MEGA PACAKGE CONTRACTS
Sr.No Pkg.No. Name of the Package Agency

.
1 C-1 Levelling & Grading M/s. SRC
(Completed)
2 C-2 Excavation (Completed) M/s. SRC
3 C-3 Reactor & Reactor M/s. HCC
Auxiliary Building
4 C-4 Turbine, Control & M/s.
Emergency Power Simplex
Supply Buildings
5 C-5 Plant Auxiliary Buildings M/s. L&T
and Structures
6 C-6 Pump house, Sea Water M/s. HCC
K
Reactor Building-1
K
N
P
P
Fully inside lined reactor containment for KKNPP: first

time in the country
Safety Feature
KKNPP: ADVANCED REACTOR
• Kudankulam Reactors are Water cooled Water moderated

Energy Reactor (VVER-1000) of Pressurized Water Reactor
(PWR) technology, which is world wide proven concept.
• VVER-1000 reactors, are the most advanced reactors

similar to the PWR’s of western design
• 21 numbers of VVER-1000 reactors are in operation with

more than 200 reactor-years of operating experience
• WER-1000 plant designs were evaluated by various

agencies such as IAEA and concluded that it is safe and
advanced design.
KKNPP: Main Technical Parameters
Sr. No. Parameter Value
1 Design Life of the Plant (Reactor Pressure Vessel) 40 years
2 Rated thermal power of the reactor Plant 3012 MWt
3 No. of Circulation loops of the reactor plant 4
4 Pressure of reactor primary system coolant at outlet of the core 15.7 MPa
5 Primary coolant temperature at the inlet to the reactor 291 oC
6 Primary coolant temperature at the outlet from the reactor 321 oC
7 Flow rate of coolant through reactor 86000 m3 / h
8 Average enrichment of the fuel reloads with U235 3.92 to 3.84 %
9 Mean burn-up of the fuel 43000 MWd/ T of U
10 Pressure of the steam generated at the outlet from the SG 6.27 MPa
11 Capacity of Generator 2 x 1000 MWe

(1111 MV.A)
KKNPP: SAFE REACTOR
• Safety has the overriding priority in all stages of the project i.e.
design,procurement,construction,commissing & operation.
• Kudankulam reactor has futuristic engineering features for the
postulated beyond design basis scenarios.
• Additional features will make reactor simple, reduction of man
machine interference, safe and reliable.
• Some of the Additional features are-
• Double Containment
• A passive system for residual heat removal
• Containment filter and venting system to protect containment
from over-pressurization
• Quick born injection system to ensure diversity in shutdown.
• Kudankulam design shall meet all national and international
environmental norms and standards.
Reactor Containment design bases
Airplane Crash
Shock Wave
Tsunami Water
flood
Seismic Effect
All possible safety measures taken into account

in the design of the Nuclear Power Plants
KKNPP Site: Levels
ACTIVE
AND
PASSIVE
SYSTEMS
OF SAFETY
IN KKNPP-
VVER 1000
NPP
Reacto
r
Pressur
e
Vessel
for
KKNPP
K
K
View of site Before start of work

N
P
P
Aug 25, 2000

K
K
N
P
KKNPP site -At the start
Leveling
P
June 16, 2001

K
K
N
P KKNPP Site: After site grading
P
Aug 15, 2001

K
K
N
P KKNPP Site: Excavation
P
Nov 30, 2001

K
K
KKNPP Site: Consolidation Grou

N
P
P
Jan25, 2002
K
K
KKNPP Site: Batching plant erect

N
P
P
Feb27, 2002
K
KKNPP Site: 31st March

K
N
P
P
2002
Mar 31, 2002
K
KKNPP Site: May 2002

K
N
P
P
May 30, 2002

K
KKNPP Site: Sep 2002

K
N
P
P
Sept 18, 2002

K
KKNPP Reactor Building: Sep 200

K
N
P
P
Sept 18, 2002

K
KKNPP Site: Feb 2003

K
N
P
P
Feb 24, 2003

K
KKNPP Site: Aug 2003

K
N
P
P
Aug 21, 2003

K
KKNPP Reactor Building: Oct 200

K
N
P
P
OCT 21, 2003

K

K
N
P
P
Feb 02, 2004

K
KKNPP Reactor Building: Feb 200

K
N
P
P
Feb 02, 2004

K
KKNPP Reactor Building: Feb 200

K
N
P
P
Feb 02, 2004

K
K
KKNPP -RB containment liner

N
P
P
Aug 18, 2004

K
K
KKNPP -RB containment liner

N
P
P
Aug 18, 2004

K
K
N
P KKNPP -RB internal Aug 2004
P
structure
Aug 18, 2004
K
KKNPP Site: Sep 2004

K
N
P
P
Sept 16, 2004

K
KKNPP Site: Dec 2004

K
N
P
P
Dec 20, 2004

K

K
N
P
P
Feb 10, 2004

K
KKNPP RB dome part-1

K
N
P
P
ea d
a h
n g e
a ll e
c h
he
Containment Dome First part being lifted in TAPP

China, a similar design of KKNPP
K
KKNPP RB dome part-2

K
d
N
P
P
h ea
e a
e n g
c h all
e
Containment Dome Second part being lifted in TAPP

China, a similar design of KKNPP
K
K
N
P
P
Major equipment erecti

K
K
N
P
Core Catcher Erection in
RB-1
P
Latest safety feature in Nuclear Reactors- Core melt

catcher at KKNPP: first of its kind in the world
K
K
N
P
Truss Cantilever
Erection in RB-1
P
K
K
N
P
Erection of Lower Plate
in RB-1
P
K
K
N
P
Erection of Support
Truss in RB-1
P
K
K
N
P
Erection of Thrust Truss
in RB-1
P
K
K
N
P Equipment Transportation
P
RPV being rolled off from barge at Mini port at KKNPP

HYDROTECHNICAL STRUCTURES (INTAKE AND OUTFALL)
Discharge channel
Part of essential load pipeline

Breakwater dyke
Chlorination plant
Shoreline protection bund

UZP
Sea Water Intake pipeline
Fish protection facility
Intake Structures
Bridge
Sea Water Inlet pipeline
Forebay
Siphon walls
Main pump house
K
K
N
P Offshore structures
P
~5 lakh cu.m . was dewatered from the temporary dyke

to facilitate construction of offshore structures in the sea
K
K
N
P
P
Commissioning Schedule
As per sanction from Government:
Unit-1 : Dec 2007
Unit-2 : Dec 2008
As per Internal Target:
Unit-1: : Mar 2007
Unit-2 : Sep 2007

KKNPP: HONOURS & ACHIEVMENTS
 “Excellent” rating for Memorandum Of Understanding
(MOU) targets for the year 2002-03 and 2003-04.
 All milestones of Ministry Of Statistics & Program
Implementation (MOSPI), for the year 2002 and 2003,
completed within schedule.
 NPCIL Safety award for the year 2002 among the
construction projects
 Greentech Silver award for Industrial Safety for year
2003
 AERB Safety Award for year 2004 among the
construction projects
 Highest accident free period among construction
projects (>30,000,000 man-hours)
KKNPP- Civil Engineering
Features
KKNPP- Civil Engineering Features
MEMBARANE WATER PROOFING

Membrane water proofing
PCC B20
• • TWO LAYERS SBS WATER PROOFING MEMBRANE
• B20 SCREED CONCRETE 20 MM THICK
• B20 SCREED CONCRETE 30MM THICK
SBS WATERPROOFING MEBARANE LAYING BELOW FOUNDATION

Screed Concrete over Membrane

Membrane Water proofing at Foundation sides
SCREW COUPLERS
Screw couplers
Universally accepted Process of extension Fabrication Unit

of Rebar
Rebar congestion due to lap can be avoided

and effective concrete placement
Available in dia of rebar 16mm & above
Reduces the construction time
Very much handy at temporary openings

which are to be closed later
Screw couplers
Type of Screw Coupler
Type- A Connecting Bar is Rotated

Screw couplers
Type- B Coupler is rotated
Additional Threading
Screw couplers
Type- C Coupler is rotated & locked with Lock nut
Additional Threading
Lock Nut
Screw couplers
Type- W Coupler welded To structural element & Bar is

rotated
Welding
Screw couplers
Cutting Metric Threads

Screw couplers
Screw splicing with Coupler

Screw couplers
Temp. Opening with Coupler

HEAVY CONCRETE
Heavy concrete
Concrete prepared with Hematite aggregate

Hematite is raw iron ore
Properties of Heavy aggregate

Chemical composition – Fe2O3
% of Iron- more than 60%
% of Iron Oxide - more than 90%
Specific Gravity- above 4.65

Heavy Concrete
Heavy Aggregate
Heavy Concrete
Heavy Concrete
Heavy Concrete
Properties of Serpentine concrete
Concrete density not less than 3650Kg / Cum
Radiation Shielding (Gamma)

Less thickness of structural element than of normal concrete
SERPENTINE CONCRETE
Serpentine Concrete
Concrete prepared with Serpentine aggregate

Metamorphic mineral occurring as small pockets in
Magnesium Dolomite
Properties of Serpentine aggregate

Chemical composition - 3MgO.2SiO2.2H20
% of Chemically bound water-13%
Compressive strength- 300Mpa
Heat conductivity coefficient- 0.895 W/(m.K)
Specific Heat- 84 KJ/(Kg.K)

Specific Gravity-2.5 to 2.8
Serpentine Concrete
Serpentine Aggregate
Serpentine Concrete
Properties of Serpentine concrete
Radiation Attenuation
Thermal Insulation
Cooling effect to the surrounding

GREEN CUTTING
Green cutting
Preparation of Construction Joint (side)

Top laitance to be removed
after final setting of Concrete
for effective bonding
Surface roughness +/- 5mm
Surface retarder Application
Just after final setting time

wash with Air Water jet
Green cutting
Preparation of Construction Joint (Top)

PRE-STRESSING
What is pre-stressing ?
Concrete is weak in Tension but can withstand more compression
Relatively high compressive strength concrete is used
Pre- compression induced by pre-stressing with HT steel wire
Net effect after the loading is only compression

Principle of Pre-stressing
W
P P
+M/Z
P/A P/A +M/Z
+ =
- M/Z
P/A - M/Z
Pre-stressing
Why pre-stressing is need for the Containment?

.Containment is the Cylindrical house for Reactor
.It is the Ultimate barrier to contain accident releases
In case of hypothetical accident the pressure inside containment may

raise to 0. 4MPa
.To with stand the pressure during accident (no part of the containment
should be in tension)
.To contain the radiation release with in the containment

Pre-stressing
Pre-stressing system For KKNPP- Freyssinet 55C15

Technical Parameter of Pre-stressing system
Greased cable un-bonded post tension Pre-stressing system

Number of tendons – U - 60Nos (every 3 degree)
H - 68 Nos (34 pairs at every 1.4m)
Number of strands in one tendon - 55 Nos
Net pre-stressing per Tendon -11.5MN
Friction coefficient -0.05 per Rad.
Wobble coefficient - 0.001 per M
Pre-stressing Jack – 3C1500F (15MN)
This system is adopted first time in the World for NPP

Pre-stressing
Pre-stressing
Technical Parameter of HDP Coated Pre-stressing Strand
Breaking load-279KN
Cross sectional area -150 Sqmm
Ultimate strength -1860MPa.
Yield strength – 1600Mpa
Modulus of Elasticity – 1.95MPa
Relaxation loss 1000hrs – 2.5% at 200C

– 3.5% at 400C
Weight per M -1.17Kg

Pre-stressing
HDP coated Pre-stressing strands

Pre-stressing
Technical Parameter of Trumplate

Weight - 140 Kg
Overall dimensions - 420 mm X 510 mm X 516 mm
Brinnel HBW hardness - 170 to 230

Pre-stressing
Trumplate Erection for U Cable

Pre-stressing
Technical Parameter of Cable Duct

Spiral sheath (formed from steel strip of 78mm)
Dia-200mm (206 for Coupler)
Thickness -0.6mm
Weight -3.66Kg/m
Steel Tube
Dia-219mm (OD)
Thickness -3.2mm
Weight -17.04Kg/m
Pre-stressing
Bell mouthing Steel pipes

Pre-stressing
Technical Parameter of Anchor Block
Overall dimensions -300mm (dia) X 160mm(thick)
Nominal tensile strength - 650 MPa
Roughness 12.5 m
Weight - 65 Kg
Pre-stressing
Technical Parameter of Wedges

Segments (parts) - 3
Overall dimensions- 26.5 mm  X 45 mm
Steel grade - 16 Mu Cr5

Pre-stressing

Mock up for Threading & Grouting (H Cable)
Pre-stressing

Cross section of the grouted Cable
Pre-stressing
Advantage of Pre-stressing system

Low friction coefficient hence less friction loss & less tendons
(Un bonded -0.05 per Rad as against 0.24 Per rad for bonded )
Re-stressing in future if necessary is possible
Cable is coated with grease & more resistant to corrosion
Single strand replacement if necessary is possible
Since grouting is done before stressing, the influence of one stand over
other during stressing is avoided.
Concrete
Design Requirement for B30 grade concrete

Modulus of Elasticity - 39000MPa
Density - 2200 to 2500Kg/Cum
Water impermeability - W6 or W8
Concrete
The concrete for KKNPP is designed for Water

impermeability of W6 or W8 as per GOST12730.05-84
Specimen specification
Dia -150mm
Height-150mm ( 40mm)
Dia -100mm (20mm)
Age -28days
Number of sample - 6
Top laitance to be removed

Concrete
Mold with Air tight

gas- cut
Concrete
Specimen is placed
inside the mold.
Gap between the mold

& specimen is sealed
with resin
Concrete
The mold with specimen

closed with rubber gas-
cut and connected to
the testing M/c
Concrete
Pressurized to 0.2MPa
Retention period
16Hrs for 40mm
12Hrs for 20mm
Pressure increment-0.2MPa
Final pressure
0.8MPa for W8
0.6MPa for W6
Criteria – No water should leak

Containment Concrete
Lift Height -2.8m Doka Self climbing

form
Grade of concrte-B50 Steel liner
Placement Temp- 190C
Fluid pressure on liner

Less than 0.015MPa
Layer-3
Layer-2
Layer-1
CIVIL WORKS: CONCRETING PROGRESS
45000
40000
35000
30000
25000
20000
15000
10000
5000
Oct-04
Mar-04
Dec-04
Feb-04
Apr-04
Aug-04
Sep-04
Jan-04
Jun-04
J ul-04
May-04
Nov-04
Total concreting done as of Mar 16, 2005 :
7.01 lakh cu.m.
Concreting done in Year 2004 : 4.01

Nuclear Government of Corporation of Power India

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Nuclear(A Government

Coal 2,600,000 t 2000 train of 1300 t each

Fossil Nuclear Site 1-4 km2

The source of Nuclear Energy lies in the

 Stage – I: 10,000 MWe through

 PHWR- Pressurized Heavy water Reactor

Moderator- Heavy Water D2O

Coolant – Heavy water

PWR- Pressurized water Reactor

FBR - Fast Breeder Reactor

Coolant – Liquid sodium

• AAA rating continuously for last 4 years

• NPCIL’s Kakrapar NPP was adjudged the best

• President’s award for the excellent performance in the

• Highest capacity factors in the world among PHWRs

• All plants of NPCIL are ISO 14000 certified.

• Highest record in the industrial safety

• Site cleared by DAE Site Section Committee

Part of essential load pipeline

Shoreline protection bund

Sea Water Intake pipeline

Fish protection facility

Sea Water Inlet pipeline

Sr.No Pkg.No. Name of the Package Agency

Fully inside lined reactor containment for KKNPP: first

• Kudankulam Reactors are Water cooled Water moderated

• VVER-1000 reactors, are the most advanced reactors

• 21 numbers of VVER-1000 reactors are in operation with

• WER-1000 plant designs were evaluated by various

1 Design Life of the Plant (Reactor Pressure Vessel) 40 years

2 Rated thermal power of the reactor Plant 3012 MWt

3 No. of Circulation loops of the reactor plant 4

5 Primary coolant temperature at the inlet to the reactor 291 oC

6 Primary coolant temperature at the outlet from the reactor 321 oC

7 Flow rate of coolant through reactor 86000 m3 / h

8 Average enrichment of the fuel reloads with U235 3.92 to 3.84 %

9 Mean burn-up of the fuel 43000 MWd/ T of U

11 Capacity of Generator 2 x 1000 MWe

All possible safety measures taken into account

View of site Before start of work

Aug 25, 2000

June 16, 2001

Aug 15, 2001

Nov 30, 2001

KKNPP Site: Consolidation Grou

KKNPP Site: Batching plant erect

KKNPP Site: 31st March

KKNPP Site: May 2002

May 30, 2002

KKNPP Site: Sep 2002

Sept 18, 2002

KKNPP Reactor Building: Sep 200

Sept 18, 2002

KKNPP Site: Feb 2003

Feb 24, 2003

KKNPP Site: Aug 2003

Aug 21, 2003

KKNPP Reactor Building: Oct 200

OCT 21, 2003

KKNPP Site: Feb 2004

Feb 02, 2004

KKNPP Reactor Building: Feb 200

Feb 02, 2004